Thermoforming method and thermoforming apparatus

ABSTRACT

Provided is a method of thermoforming a molding material to have a bent portion and a flat portion extending from the bent portion. The method includes: placing the molding material on a bending mold, the bending mold having a curved surface; and forming the bent portion of the molding material by heating a portion of the molding material at least to a fluidization temperature such that the portion of the molding material bends due to the weight of the flat portion of the molding material to form the bent portion according to a shape of the bending mold.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/221,546, filed Jul. 27, 2016, which claims priority to and thebenefit of Korean Patent Application No. 10-2015-0141691, filed on Oct.8, 2015 in the Korean Intellectual Property Office, the entire contentof both of which is hereby incorporated by reference.

BACKGROUND 1. Field

Embodiments of the present disclosure relate to a thermoforming methodand a thermoforming apparatus.

2. Description of the Related Art

Thermoforming is a method for manufacturing a molding by deforming ashape of a molding material in a state in which a molding material isheated to be fluidized. Extrusion molding may be applied to athermoplastic resin (e.g., polyethylene, chloride resin, etc.).

Recently, bended and/or bendable display apparatuses have beendeveloped. These display apparatus include bended and/or bendabledisplay panels and various functional layers.

SUMMARY

Embodiments of the present disclosure provide a thermoforming method anda thermoforming apparatus used to manufacture a molding having a bendedor curved shape.

An embodiment of the inventive concept provides a method forthermoforming a molding material to have a bent part and a flat partextending from the bent part. The method includes: placing the moldingmaterial on a bending mold, the bending mold having a curved surface;and forming the bent portion of the molding material by heating aportion of the molding material at least to a fluidization temperaturesuch that the portion of the molding material bends to the weight of theflat portion of the molding material to form the bent portion accordingto a shape of the bending mold.

In an embodiment, a lower surface of the bent portion may be bentaccording to the curved surface of the bending mold.

In an embodiment, the flat portion may include a first end extendingfrom the bent portion and a second end opposite the first end, and theforming of the bent portion may include the second end rotating withrespect to the bending mold due to the weight of the flat portion.

In an embodiment, the forming of the bent portion may further include:arranging a support member under the second end such that and thesupport member supports the second end; and moving the support membersuch that the support member does not overlap the second end in avertical direction and the second end start is permitted to rotate.

In an embodiment, the bending mold may extend in a first direction, andthe flat portion may include: a first flat portion extending from thebent part in the first; and a second flat portion extending from thebent portion in a second direction opposite to the first direction.

In an embodiment, the second end rotating may include the second ends ofthe first and second flat portions rotating clockwise andcounterclockwise, respectively.

In an embodiment, the forming of the bent portion may further includecoupling a weight to the flat portion.

In an embodiment, the flat portion may include: a first end extendingfrom the bent portion; and a second end opposite to the first end.

In an embodiment, the forming of the bent portion may further includethe weight being pulled by a magnetic force of with a magnet arrangedalong a rotation path of the second end opposite to a center of the bentportion.

In an embodiment, the method for thermoforming may further includecooling the bent portion after the forming of the bent portion.

In an embodiment, the method for thermoforming may further includecutting the molding material along a bending axis of the bent portion toform first and second moldings.

In an embodiment, the bent portion may include first and second bentportions separated by the bending axis. The flat portion may includefirst and second flat portions respectively extending from the first andsecond bent portions in different directions. The first molding mayinclude the first bent portion and the first flat portion, and thesecond molding may include the second bent portion and the second flatportion.

In an embodiment, the first and second moldings may have substantiallythe same shape.

In an embodiment, the molding material may include a middle flat portionbetween the first and second bent portions. The first and second bendingmolds may extend from opposite sides of a flat mold corresponding to themiddle flat portion, and the placing of the molding material may includerespectively arranging the first and second bent portions on the firstand second bending molds.

In an embodiment, each of the first and second bending molds may extendin a first direction. The flat portion may include: a first flat portionextending from the first bent portion in a second direction differentfrom the first direction; and a second flat portion extending from thesecond bent portion in a third direction opposite to the seconddirection.

In an embodiment, the heating of the bent portion of the moldingmaterial may include heating the bent portion up to at least afluidization temperature of the bent portion.

In an embodiment of the inventive concept, an apparatus forthermoforming a molding material to have a bent portion and a flatportion extending from the bent portion includes: a base stage; abending mold on the base stage, and having a curved upper surface; atemperature controller configured to heat the molding material such thatthe portion is fluidized, wherein the fluidized bent portion isconfigured to be bent due to the weight of the flat portion.

In an embodiment, the flat portion may have a first end extending fromthe bent portion and a second end opposite to the first end, and whenthe bent portion bends, the second end may rotate about the bendingmold.

In an embodiment, the apparatus for thermoforming may further include asupport member. In a first state, the support member may be under theflat portion in a vertical direction such that the flat portion issupported, and in a second state, the support member does not overlapthe second end in the vertical direction such that the flat portionrotating.

In an embodiment, the apparatus for thermoforming may further include aweight coupled to the flat portion.

In an embodiment, the base stage may further include a sliding surface,and when the bent portion bends, the weight may slide along the slidingsurface.

In an embodiment, the apparatus for thermoforming may further include amagnet beneath the sliding surface and arranged along a rotation path ofthe second end. The weight may include a magnetic material, and themagnet is configured to apply a force to the weight in a direction awayfrom a center of the bent portion.

In an embodiment, the temperature controller may be configured to coolthe bent portion to the fluidization temperature of the bent portion orlower.

In an embodiment, the bending mold may be spaced from the flat portionalong a plane.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the inventive concept and are incorporated in andconstitute a part of this specification. The drawings illustrateexemplary embodiments of the inventive concept and, together with thedescription, serve to explain aspects and features of the inventiveconcept. In the drawings:

FIG. 1A is a plan view of a thermoforming apparatus according to anembodiment of the inventive concept;

FIG. 1B is a partial cross-sectional perspective view of thethermoforming apparatus taken along the line I-I′ of FIG. 1A;

FIG. 2 is a flowchart of a thermoforming method according to anembodiment of the inventive concept;

FIG. 3A is an illustration of step S1 of FIG. 2;

FIG. 3B is an illustration of steps S2 and S3 of FIG. 2.

FIG. 3C is an illustration of step S4 of FIG. 2;

FIG. 4 is an exploded perspective view of a display apparatus to whichthe molding illustrated in FIG. 3C is applied;

FIGS. 5A-5C are illustrations of a forming process according to anembodiment of the inventive concept; and

FIG. 6 is an exploded perspective view of a display apparatus to whichthe molding illustrated in FIG. 5C is applied.

DETAILED DESCRIPTION

The inventive concept may be modified in several different forms, andonly certain embodiments will be exemplified in the drawings anddescribed in detail. It is to be understood that embodiments of thepresent invention are not limited to the described embodiments, and thepresent disclosure is intended to cover various modifications andequivalent arrangements included within the spirit and scope of thedisclosure, including the appended claims and their equivalents.

In describing the drawings, like reference numerals refer to likeelements throughout. In the drawings, the dimensions and sizes of thestructures and components may be exaggerated, omitted, or schematicallyillustrated for convenience of description and clarity. It will beunderstood that, although the terms first, second, third, etc. may beused herein to describe various elements, components, regions, layers,and/or sections, these elements, components, regions, layers, and/orsections should not be limited by these terms. These terms are used todistinguish one element, component, region, layer, or section fromanother element, component, region, layer, or section. Thus, a firstelement, component, region, layer, or section discussed below could betermed a second element, component, region, layer, or section withoutdeparting from the teachings of example embodiments. The terms insingular form may include plural forms unless referred to in thecontrary. For example, as used herein, the singular forms “a” and “an”are intended to include the plural forms as well, unless the contextclearly indicates otherwise.

It will be further understood that the terms “includes,” “including,”“comprises,” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components but do not preclude the presence or additionof one or more other features, integers, steps, operations, elements,components, and/or groups thereof. Furthermore, it will be understoodthat when an element or layer is referred to as being “on,” “connectedto,” or “coupled to” another element or layer, it may be directly on,connected, or coupled to the other element or layer or one or moreintervening elements or layers may also be present. When an element isreferred to as being “directly on,” “directly connected to,” or“directly coupled to” another element or layer, there are no interveningelements or layers present. For example, when a first element isdescribed as being “coupled” or “connected” to a second element, thefirst element may be directly coupled or connected to the second elementor the first element may be indirectly coupled or connected to thesecond element via one or more intervening elements. As used herein, theterm “and/or” includes any and all combinations of one or more of theassociated listed items. Further, the use of “may” when describingembodiments of the present invention relates to “one or more embodimentsof the present invention.” Expressions, such as “at least one of,” whenpreceding a list of elements, modify the entire list of elements and donot modify the individual elements of the list. Also, the term“exemplary” is intended to refer to an example or illustration. As usedherein, the terms “use,” “using,” and “used” may be consideredsynonymous with the terms “utilize,” “utilizing,” and “utilized,”respectively.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,”“upper,” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” or “over” the otherelements or features. Thus, the term “below” may encompass both anorientation of above and below. The device may be otherwise oriented(rotated 90 degrees or at other orientations), and the spatiallyrelative descriptors used herein should be interpreted accordingly.

Hereinafter, exemplary embodiments of the inventive concept will bedescribed in more detail with reference to the accompanying drawings.

FIG. 1A is a plan view of a thermoforming apparatus according to anembodiment of the inventive concept, and FIG. 1B is a partialcross-sectional perspective view of the thermoforming apparatus takenalong the line I-I′ of FIG. 1A.

Referring to FIGS. 1A and 1B, a thermoforming apparatus 1000 includes abase stage 200 and a mold part 300 (e.g., a mold).

The base stage 200 may include a bottom part 210 (e.g., a bottom or abottom portion) and a side part 220 (e.g., a side or a side portion).

In one embodiment of the inventive concept, the bottom part 210, whenviewed in a plan view, may have a rectangular shape having a pair ofparallel long sides and a pair of parallel short sides. The long sidesare, for example, parallel to a first direction DR1, and the short sidesare, for example, parallel to a second direction DR2. The first andsecond directions DR1 and DR2, for example, may cross each other at aright angle. However, the shape of the bottom part 210 is not limited toa rectangle and may be variously changed.

The side part 220 may extend in a vertical direction from the long sidesand short sides of the bottom part 210. The vertical direction may be athird direction DR3 perpendicular to the first and second directions DR1and DR2.

For example, the side part 220 may include a first side part 220 a(e.g., a first side or a first side portion) extending in the thirddirection DR3 from the short sides of the bottom part 210 and a secondside part 220 b (e.g., a second side or a second side portion) extendingin the third direction DR3 from the long sides of the bottom part 210.

The base stage 200 may further include a sliding surface 230. Thesliding surface 230 may have a curved surface extending generally alongthe second direction DR2 and the third direction DR3. In one embodiment,the sliding surface 230 is downwardly concave. A cross-section of thesliding surface 230 taken along the first and third directions DR1 andDR3 may be approximately a downwardly concave circular arc. A rotationspace 240 (e.g., a rotation area or void) may be defined in the basestage 200 by (e.g., above) the sliding surface 230. The sliding surface230 will be further described later.

In one embodiment of the inventive concept, the mold part 300 extends inthe third direction DR3 from the base stage 200. The mold part 300includes a bending mold 310 (e.g., a bent or curved mold) and aconnection part 320 (e.g., a connector). The connection part 320 extendsin the third direction DR3 from the base stage 200. A lower end of theconnection part 320 may be connected with or may extend from (e.g., maybe integral with) the sliding surface 230.

The connection part 320 may have or may be, for example, a wallextending in the second direction DR2, and both side ends of theconnection part 320 may extend parallel to (e.g., may extend in) thesecond direction DR2 to be connected with the second side parts 220 b.The rotation space 240 may be divided (e.g., may be divided into twoparts or areas) along the first direction DR1 by the connection part320.

In one embodiment of the inventive concept, the bending mold 310 isdisposed or arranged on an upper end of the connection part 320. Anupper surface 311 of the bending mold 310 is curved. The upper surface311 may extend in the second direction DR2 and may have an upwardlyconvex semi-circular shape (e.g., may have an upwardly convexsemi-circular shape protruding in the third direction DR3).

In an embodiment of the inventive concept, the thermoforming apparatus1000 may further include a support part 400 (e.g., a support or asupport member). The support part 400 may be, for example, provided as apair (e.g., two support parts 400 may be provided in the thermoformingapparatus 1000), and the support parts 400 may be respectively coupledto the first side parts 220 a. For example, the support parts 400 may becoupled to (e.g., inserted into) openings 221 (e.g., holes, slits, orgrooves) defined in the first side parts 220 a such that the supportparts 400 are configured to move in the first direction DR1 wheninserted into the openings 221. The support part 400 may, for example,have a plate shape extending in the second direction DR2. The supportpart 400 will be further described later.

FIG. 2 is a flowchart of a thermoforming method according to anembodiment of the inventive concept, FIG. 3A is an illustration of stepS1 of FIG. 2, FIG. 3B is an illustration of steps S2 and S3 of FIG. 2,and FIG. 3C is an illustration of step S4 of FIG. 2.

Referring to FIGS. 2-3C, a molding material 103 (e.g., a molding blank)is disposed in the thermoforming apparatus 1000.

The molding material 103 may be subdivided into a middle flat part 115(e.g., a flat portion) to be bent through a thermoforming methodperformed by using the thermoforming apparatus 1000 and an adjacent flatpart (e.g., an adjacent flat portion) that is substantially flat. In oneembodiment of the inventive concept, the adjacent flat part may includea first flat part 121 (e.g., first flat portion) extending in the firstdirection DR1 from an end of the middle flat portion 115 and a secondflat part 122 (e.g., a second flat portion) extending in a fourthdirection DR4 opposite to the first direction from an opposite end ofthe middle flat part 115. The molding material 103 may include or maybe, for example, glass and/or may also include or may be a thermoplasticresin, such as polycarbonate.

In one embodiment of the inventive concept, the molding material 103 isdisposed in the thermoforming apparatus 1000 such that the middle flatportion 115 is disposed on the bending mold 310 (S1). A lower surface ofthe middle flat portion 115 may directly contact, for example, the uppersurface 311 of the bending mold 310.

In one embodiment of the inventive concept, the thermoforming apparatus1000 may further include a weight 500. The weight 500 may be coupled toboth ends of the molding material 103.

For example, the first flat part 121 may have a first end 121 d and asecond end 121 e. The first end 121 d of the first flat part 121 isconnected to the middle flat portion 115, and the second end 121 e ofthe first flat part 121 is opposite to the first end 121 d in adirection away from the middle flat portion 115 (e.g., in the firstdirection DR1). The first end 121 d and the second end 121 e of thefirst flat part 121 may extend in the second direction DR2 and face eachother. Similarly, the second flat part 122 have a first end 122 d and asecond end 122 e.

In one embodiment of the inventive concept, the weights 500 are providedin a pair (e.g., two weights 500 are provided), and ones of the weights500 may be respectively coupled to the second ends 121 e and 122 e. Eachof the weights 500 may extend, for example, in the second direction DR2.Grooves, into which the second ends 121 e and 122 e may be inserted, aredefined in the weights 500. Also, a stopper, which prevents the weights500 from becoming unintentionally separated from the second ends 121 eand 122 e, may be provided in the weights 500.

In a first state, the support parts 400 may be disposed such that theyprotrude towards the mold part 300 from the first side parts 220 a(e.g., the supports parts 400 may be positioned in the first side parts220 a such that they protrude into the rotation spaces 240). The supportparts 400 support the second ends 121 e and 122 e. Ones of the supportparts 400 are respectively disposed under the second ends 121 e and 122e. For example, the ones of the support parts 400 respectively overlapthe second ends 121 e and 122 e in the third direction DR3.

In one embodiment of the inventive concept, the support parts 400 maysupport the second ends 121 e and 122 e through the weights 500. Forexample, upper surfaces of the support parts 400 contact lower surfacesof the weights 500 to support the lower surfaces of the weights 500 and,thus, also support the second ends 121 e and 122 e.

Referring to FIG. 3B, the thermoforming apparatus 1000 may furtherinclude a temperature control unit 600 (e.g., a temperature controller).The temperature control unit 600 may be disposed at or under the middleflat part 115 and may extend in the second direction DR2 along themiddle flat part 115. The temperature control unit 600 may heat themiddle flat part 115 up to a fluidization temperature or higher suchthat the middle flat part 115 is fluidized. At the fluidizationtemperature or higher, the molding material 103 may be fluidized.

In one embodiment of the inventive concept, the temperature control unit600 may include a heater. The heater may provide heat to (e.g., mayheat) the middle flat part 115 by directly contacting the middle flatpart 115, through another member that contacts the middle flat part 115(e.g., the heater may heat the middle flat part 115 via directconduction or via conduction through an intermediate member), or in astate of being spaced from (e.g., spaced a predetermined distance from)the middle flat part 115. Also, in another embodiment of the inventiveconcept, the temperature control unit 600 may be provided in the bendingmold 310 and may provide heat to the middle flat part 115 through theupper surface 311 of the bending mold 310.

In a second state, the support parts 400 move in a direction away fromthe mold part 300 (e.g., the support parts 400 move to be outside of therotation spaces 240). Accordingly, the support parts 400 do not overlapthe second ends 121 e and 122 e in the third direction DR3 such that thesupport parts 400 do not support the second ends 121 e and 122 e. As thesupport parts 400 move to the second state, as further described below,the second ends 121 e and 122 e may begin to rotate.

As the middle flat part 115 is heated and fluidized, the middle flatpart 115 may bend due to the weight of the first and second flat parts121 and 122 (S3). For example, because the middle flat part 115 isfluidized to increase its flexibility while the first and second flatparts 121 and 122 retain their rigidity, the first and second flat parts121 and 122 are respectively rotated clockwise and counterclockwise dueto the gravitational force applied to the first and second flat parts121 and 122. Accordingly, the middle flat part 115 is bent or curved toform the bent part 110. As a result, the middle flat part 115 may bebent around the bending mold 310 to form the bent part 110.

For example, the second ends 121 e and 122 e may be respectively rotatedabout the bending mold 310 (or the center of the middle flat part115/the bent part 110) clockwise and counterclockwise.

The weights 500 may slide along the sliding surface 230. The slidingsurface 230 guides the rotation of the second ends 121 e and 122 e.Accordingly, the amount of force applied to the middle flat part 115 maybe reduced or limited, and the middle flat part 115 may be sufficientlyand accurately bent to form the bent part 110.

As the first and second flat parts 121 and 122 rotate, a first forcefacing toward center of the middle flat part 115 may be applied to themiddle flat part 115 from the first and second flat parts 121 and 122.The first force is applied to the middle flat part 115 as a horizontalpressure, and the shape of the middle flat part 115 may change or bedistorted due to the first force.

In one embodiment of the inventive concept, the thermoforming apparatus1000 may further include a magnetic part 700 (e.g., a magnet) whichreduces or cancels the first force. The magnetic part 700 may beprovided in (e.g., may be encased in) the base stage 200. In oneembodiment of the inventive concept, the magnetic part 700 may bedisposed along or corresponding to the rotation trajectory or path ofthe second ends 121 e and 122 e. The magnetic part 700 may have, forexample, a shape corresponding to the sliding surface 230 and may bedisposed adjacent to or under the sliding surface 230. In one embodimentof the inventive concept, the weights 500 may include a magneticmaterial. Accordingly, a second force, which pulls the weights in adirection away from the center of the middle flat part 115 due to themagnetic force between the weights 500 and the magnetic part 700, isapplied to the weights 500. The second force may reduce or cancel thefirst force. Accordingly, horizontal pressure may not be applied to themiddle flat part 115, and the middle flat part 115 may be sufficientlyand accurately bent to form the bent part 110.

As the middle flat part 115 bends, the upper surface 311 of the bendingmold 310 supports the lower surface of the middle flat part 115.Accordingly, when the first and second flat parts 121 and 122 are fullyrotated (e.g., when the rotation of the first and second flat parts 121and 122 is completed), the bent part 110 may be bent to be upwardlyconvex corresponding to the upper surface 311 of the bending mold 310.That is, the shape of the bent part 110 may be determined by the bendingmold 310.

After the rotation of the first and second flat parts 121 and 122, thetemperature control unit 600 cools the bent part 110 down to thefluidization temperature or less. In one embodiment of the inventiveconcept, the temperature control unit 600 may include a cooler. Thecooler may cool the bent part 110 by directly contacting the bent part110, through another member contacting the bent part 110, or in a stateof being spaced from (e.g., spaced a predetermined distance from) thebent part 110.

In one embodiment of the inventive concept, the thermoforming apparatus1000 may further include a seal cover. The seal cover may be disposedover the side part 220 and may seal the rotation spaces 240 by beingcoupled to the side part 220. Accordingly, when the temperature controlunit 600 heats the molding material 103, the sliding surface 230, andthe mold part 300, these components may not be damaged by externalwater, oxygen, etc.

Then, as illustrated in FIG. 3C, in one embodiment of the inventiveconcept, the bent part 110, after being removed from the thermoformingapparatus 1000, is cut along a bending axis BA (S4). The bending axis BAmay pass through the center of the bent part 110 along the seconddirection DR2. The bent part 110 may be subdivided into a first bentpart 111 and a second bent part 112 (e.g., a first bent portion and asecond bent portion, respectively) with respect to the bending axis BA.For example, the border between the first and second bent parts 111 and112 may be defined by the bending axis BA (e.g., the first and secondbent parts 111 and 112 may be separated by the bending axis BA).

First and second moldings 101 and 102 may be formed by cutting themolding material 100 (e.g., by cutting the bent part 110). The firstmolding 101 may include the first bent part 111 and the first flat part121, and the second molding 102 may include the second bent part 112 andthe second flat part 122. In one embodiment of the inventive concept,the first and second moldings 101 and 102 may have the same orsubstantially similar shapes.

As described above, the middle flat part 115 is heated to be fluidizedand is then bent due to the weight of the adjacent flat part or parts.Accordingly, a molding including the bent part 110 having a relativelylarge area may be efficiently manufactured. Also, in comparison withother extrusion molding or injection molding forming methods, themolding material 103 may not be damaged because the forming is performedby using less pressure. Furthermore, because a burr, which is oftengenerated at a border between two molds used in the injection moldingprocess, is not generated, an additional grinding process for removingthe burr may be omitted. Even further, because the first and secondmoldings 101 and 102 are formed from one molding material 103 (e.g.,from a single molding piece or blank), a process yield may be improvedcompared to other forming method.

In one embodiment of the inventive concept, the shape (or curvature) ofthe bent part 110 may be effectively determined by the upper surface 311of the bending mold 310. Also, the bending speed or rate of the moldingmaterial 103 may be controlled or determined, at least in part, by theweights 500. By controlling the bending speed or rate, the thickness ofthe bent part 110 may be controlled and the molding material 103 may notbe damaged during the bending process.

FIG. 4 is an exploded perspective view of a display apparatus to whichthe molding illustrated in FIG. 3C is applied.

The first molding 101 may be applied to a display apparatus DS as acover member 101. The display apparatus DS includes a display member DP,the cover member 101, and an accommodation member CM. The display memberDP is disposed between the accommodation member CM and the cover member101.

The display member DP receives power to display an image. The displaymember DP is subdivided, in a plane, into a display area DA and aperipheral area NDA. The display area DA is generally defined as acenter of the display member DP. Images are displayed at the displayarea DA.

The peripheral area NDA is defined adjacent to the display area DA. Theperipheral area NDA may be defined as a frame shape surrounding thedisplay area DA. Images are not displayed at the peripheral area NDA.

The display member DP may include a display panel and a touch panel. Thedisplay panel generates an image according to an electrical signal. Thedisplay panel is not specifically limited, and, the display panel maybe, for example, an organic light emitting display panel, a liquidcrystal display panel, a plasma display panel, an electrophoreticdisplay panel, an electrowetting display panel, etc.

The touch panel calculates or determines a coordinate (e.g., a location)of an external input. The external input includes a stylus pen and/or apressure due to a finger of a user. The external pressure may besubstantially generated on the cover member 101.

Also, the touch panel is not specifically limited to any one method ortype, and may be, for example, a resistive touch panel, a capacitivetouch panel, or the like. Also, in a display apparatus according to anembodiment of the inventive concept, the touch panel may not beincluded.

The cover member 101 is disposed on the display member DP to cover thedisplay member DP. The cover member 101 may be a window (e.g., a windowmember) of the display apparatus DS.

The cover member 101 according to one embodiment of the inventiveconcept may stably protect the display member DP from an external shockapplied to the display area DA.

The accommodation member CM is disposed under the display member DP. Theaccommodation member CM defines an accommodation space. In theaccommodation space defined by the accommodation member CM, the displaymember DP and various components for driving the display apparatus DSmay be accommodated together.

The accommodation member CM is coupled to the cover member 101 to definethe appearance (e.g., the external appearance) of the display apparatusDS. The accommodation member CM may have various, suitable shapes,including shapes that define the accommodation space and may be coupledto the cover member 101; however, the shape of the accommodation memberCM is not limited to any particular shape. The accommodation member CMand the cover member 101 stably protect the components accommodatedtherein from external shocks.

FIGS. 5A-5C are illustrate a forming process according to one embodimentof the inventive concept.

Referring to FIG. 5A, in one embodiment of the inventive concept, a moldpart 301 (e.g., a mold) includes first and second bending molds 310 aand 310 b and a flat mold 313. The first and second bending molds 310 aand 310 b are spaced from each other in a first direction DR1, and theflat mold 313 may be interposed between the first and second bendingmolds 310 a and 310 b in the first direction DR1. The first bending mold310 a may extend in a first direction DR1 from the flat mold 313, andthe second bending mold 310 b may extend in a fourth direction DR4(e.g., a direction opposite the first direction DR1) from the flat mold313.

In one embodiment of the inventive concept, the molding material 103 maybe subdivided into (e.g., may include) first and second bent parts 113and 114 (e.g., first and second bending portions, respectively), whichare to be bent through a thermoforming method, and a flat part (e.g., aflat portion), which is formed substantially flat (e.g., which is toremain flat or to not be bent). The flat part, in a plane, includes amiddle flat part 115 (e.g., a middle flat portion) interposed betweenthe first and second bent parts 113 and 114, a first flat part 123(e.g., a first flat portion) extending in the first direction DR1 fromthe first bent part 113, and a second flat part 124 (e.g., a second flatportion) extending in the fourth direction DR4 from the second bent part114.

In a first state, support parts 400 (e.g., supports or supporters)support respective second ends 123 e and 124 e of the first and secondflat parts 123 and 124. The support parts 400 are respectively disposedunder the second ends 123 e and 124 e. For example, the support parts400 respectively overlap the second ends 123 e and 124 e in the thirddirection DR3.

In one embodiment of the inventive concept, the support parts 400 maysupport the second ends 123 e and 124 e through weights 500. Forexample, upper surfaces of the support parts 400 contact lower surfacesof the weights 500 and support the lower surfaces of the weights 500 tosupport the second ends 123 e and 124 e.

Referring to FIG. 5B, temperature control units 600 (e.g., temperaturecontrollers) may be respectively disposed at or under the first andsecond bent parts 113 and 114 and extend in the second direction DR2along the first and second bent parts 113 and 114. The temperaturecontrol units 600 may heat the first and second bent parts 113 and 114up to the fluidization temperature or higher. At the fluidizationtemperature or higher, the molding material 103 may be fluidized.

In a second state, the support parts 400 move in a direction opposite to(e.g., move away from) the mold part 301. Accordingly, the support parts400 do not overlap the second ends 123 e and 124 e in the thirddirection DR3 such that the support parts 400 do not support the secondends 123 e and 124 e. As the support parts 400 move to the second state,as further described below, the second ends 123 e and 124 e may begin torotate.

As the first and second bent parts 113 and 114 are fluidized, the firstand second bent parts 113 and 114 may bend due to the weight of thefirst and second flat parts 123 and 124. For example, because the firstand second bent parts 113 and 114 are fluidized to be flexible while thefirst and second flat parts 123 and 124 retain their rigidity, the firstand second flat parts 123 and 124 are respectively rotated clockwise andcounterclockwise due to the gravitational force applied to the first andsecond flat parts 123 and 124. Accordingly, the first and second bentparts 113 and 114 are bent (e.g., ends of the middle flat part 115 bendto form the first and second bent parts 113 and 114).

For example, the second ends 123 e and 124 e may respectively rotateabout the bending mold 310 clockwise and counterclockwise.

As the first and second bent parts 113 and 114 bend, upper surfaces 311a and 311 b of the first and second bending molds 310 a and 310 brespectively support lower surfaces of the first and second bent parts113 and 114. Accordingly, when the first and second flat parts 123 and124 have finished rotating, the first and second bent parts 113 and 114may be bent to be upwardly convex corresponding to the upper surfaces311 a and 311 b of the first and second bending mold 310 a and 310 b.

Then, the temperature control units 600 cool the first and second bentparts 113 and 114 down to the fluidization temperature or lower.

Then, as illustrated in FIG. 5C, in one embodiment of the inventiveconcept, the molding material 103, which has been bent as describedabove, may be removed from the thermoforming apparatus 1000 and thefirst and second flat parts 123 and 124 may be cut (e.g., the first andsecond flat parts 123 and 124 may be removed or cut from the molding103). A molding 104 may be formed by removing (e.g., by cutting) all orpart of the first and second flat parts 123 and 124 from the first andsecond bent parts 113 and 114, respectively.

FIG. 6 is an exploded perspective view of a display apparatus to whichthe molding illustrated in FIG. 5C is applied.

As illustrated in FIG. 6, a molding 104 may be applied to (e.g.,included in) a display apparatus DS-1 as a cover member 104. Because thedisplay apparatus DS-1 is substantially similar to or the same as thedisplay apparatus illustrated in FIG. 4, overlapping descriptionsthereof may not be provided.

According to the above-mentioned description, the bent part may be bentor formed by the weight of the flat part and may be bent to have a shapecorresponding to the upper surface of the bending mold. Thus, the bentshape of the bent part may be effectively formed without defect, theprocess time for such forming processes may be reduced, and the processcosts may be reduced. Also, a bent part having a relatively large areamay be effectively formed.

While exemplary embodiments are described above, a person skilled in theart would understand that many modifications and variations may be madeto the described embodiments without departing from the spirit and scopeof the present invention as defined in the following claims and theirequivalents.

What is claimed is:
 1. A apparatus for thermoforming a molding materialto have a bent portion and a flat portion extending from the bentportion, the apparatus comprising: a base stage; a bending mold on thebase stage, and having a curved upper surface; and a temperaturecontroller configured to heat the molding material such that the bentportion is fluidized, wherein the fluidized bent portion is configuredto be bent due to the weight of the flat portion.
 2. The apparatus ofclaim 1, wherein the flat portion has a first end extending from thebent portion and a second end opposite to the first end, and whereinwhen the bent portion bends, the second end rotates about the bendingmold.
 3. The apparatus of claim 2, further comprising a support member,wherein, in a first state, the support member is under the flat portionin a vertical direction such that the flat portion is supported, andwherein, in a second state, the support member does not overlap thesecond end in the vertical direction such that the flat portion rotates.4. The apparatus of claim 1 further comprising a weight coupled to theflat portion.
 5. The apparatus of claim 4, wherein the base stagefurther comprises a sliding surface, and wherein when the bent partbends, the weight slides along the sliding surface.
 6. The apparatus ofclaim 5 further comprising a magnet beneath the sliding surface andarranged along a rotation path of the second end, wherein the weightcomprises a magnetic material, and the magnet is configured to apply aforce to the weight in a direction away from a center of the bentportion.
 7. The apparatus of claim 1, wherein the temperature controlleris configured to cool the bent portion to the fluidization temperatureof the bent portion or lower.
 8. The apparatus of claim 1, wherein thebending mold is spaced from the flat portion along a plane.